Knockdown box



Nov. 5, 1935. s. N. LEOPOLD 2,019,787

KNOCKDOWN BOX Filed'March 18,. 1953 2 Sheets-Sheeil 1 NOV. 5, 1935. s. N LEOPOLD 2,019,787

KNOCKDOWN BOX Filed March 18, 1933 2 Sheets-Sheet 2 i l l.

. mw/H60 Zd,

Patented Nov. 5; 1935 UNITED STATES 1' ix.'1"|a'.l-rrv ori-ics KNOCKDOWN BOX Samuel N. Leopold, Chicago, Ill., assignor to Morris Paper Mills, Morris, Ill., a corporation of Illinois Applicatimn-Mnircn 1s, 1933, serial No. 661,483

2 claims. (ci. zza-41) The present invention relates to the art of packaging materials, and has particular reference to improvements in the production of packages especially adapted for use in connection with frozen products, such as ice cream, and the like.

A primary object of the invention is to provide an improved method and container'for packaging ice cream and similar commodities.

An additional object is to provide an improved ice cream container in connection with which it is not necessary to employ metallic securing or supporting means.

A still further object is to provide a collapsible e container which is economical, easily manufactured, and easily erected for use.

These-and. other objects will be apparent from a consideration of the following and illustrative and explanatory description and by reference to the accompanying drawings, in which Fig. 1 is a cross-sectional view of a container constructed in accordance with my invention and shown in Fig. 2;

Fig. 6 is a plan view showing a blankY cutand scored so that it may be formed into the inner container or inse shown in Fig. 3;

j Fig. 7 is a View of the blank showing partial `erection ofthe blank disclosed in Fig. 5;

Fig. 8 is a perspective view showing a full erection of the blank shown in Fig. 5;

Fig. 9 is a still further disclosure of the method of fdrming the finished container;

Fig. 10 shows the last step in forming the collapsed container;

Fig. 11 discloses the outer container in par- I tially erected position;

, Fig. 12 is a perspective view of a container constructed in accordance with my invention and having eight vertical sides; and

Fig. 13 is a plan-view of a blank from which the. outer casing of the container shown in Fig. 12

is constructed.

It has been recognized heretofore that the use of bre containers for packaging materials such as'ice cream is highly advantageous. The me# tallic cans which'were used for this purpose prior i to the introduction of fibrous containers, and

which are still used to a considerable extent, present a number of problems. As an example, it is necessary that the'cans be returned from the dis- 5 penser of the ice cream' to the producer of the same. Also, a complete sterilization is required before the containers may be subsequently used.

The fibre containers which have met with considerable success in packaging frozen materials, 10 such as ice cream, areA generally formed of a single thickness. cylinder having on its bottom section a metallic ring or binding portion which serves to form a base for the container, maintaining it in predetermined shape and position 15 and providing a suitable base on which to rest the carton', which base will -not be deleteriously affected by casual .moisture or by. conditions met -in handling during packing, freezing and shipy the class described which is collapsible into flattened condition and in connection with which it is not necessary to employ auxiliary base members vsuch as metallic rings and the like. The' container is of such structure that it may be formed economically and rapidly.

As shown in Figs. l and 2 of the drawings my container includes a continuous outer body section I0 of polygonal shape and including a bottom section II and a non-continuous inner body section or liner I2 adapted to assume a similar shape upon insertion of a detached bottom or disk i3. 85

To form the outer container a single blankl of- -material'may be cut and scored in the manner shown in Fig. 7, for example. 'Ihat is, a blank of cardboard or other suitable fibrous material is cut to form opposite or complementary side 40v sections I4, each of which is scored to form a plurality of individual side sections I5, I5 and I1, the sections I .'i` and Il constituting outer Wings or side sections while the sections I6 form intermediate side sections. To the outer edges of one 45 of the sections I5 and one of the sections I'i are secured attaching wings or portions I8 and I9 respectively. In the embodiment shown in the drawings these wings are both attached to one side of the blank, while it is quite possible that one or both of the attaching portions could be secured along the corresponding edge or edges of the opposite side of the blank. The side sec-y tions Il are spaced apart and unitedtogether by i15 tom section II is simi bottom section, which constitutes the base for the container, is of polygonal shape and has integrally connected thereto along its free edges a plurality of flaps 2II, the function of which will 5 be Adescribed more specifically hereinafter. That is, between sections I5 and along the free edges of the polygonal bottom section II are provided iaps which are connected to the bottom section along a score line, the two flaps between sections I5 being separate and independentlymovable. Similarly, between the sections I'I are provided two independently foldable flaps 2li.

'I'he outer container III shown particularly in Figs. l and 2 is of hexagonal shape and the botlarlyformed with six sides. As shown inFig. 'I the complementary side sections I4 are integrally connected with opposite and parallel sides of the bottom section, a score line defining the point of jointure. In addition.' the bottom section I I is provided with a score line 2I which divides the bottom section in half along a line parallel to those edges of the bottom section to which the side sections I4 are attached. It will be seen that the score line 2| terminates at the-point of meeting of the free edges of the bottom` section, and more particularly between the independently movable aps 20.

Figs. 7 to 11 disclose the method by which the outer container III isformed from the blank shown in Fig. 5. A first step in the operation of assembling or forming the outer container consists of folding the independently movable naps 20 into substantiallyerect position as shown in Fig. 7. As a second stage in the operation, the bottom section' I I is folded along the central score line 2l, the sidesections I4 being moved toward each other and the bottom section being raised into substantially inverted V-shape and then` into parallel contiguous relation. The complementary side sections I4 are then folded over in the manner of closing a book into parallel and contiguous relation in the manner shown in Fig. 9. When the complementary side sections Il are folded together each of the attaching flaps I9 5 is bent over against the outer face of its opposed.V A

' side section and secured thereto as shown in Fig. 10. The attaching portions may be stitched to the corresponding side section or they may be stapled or otherwise attached thereto by wellknown means, as will be understood by those skilled in the art. thereby completing the formation of the outer container.

'I'he completed outer container shown in Fig. 10 is in the collapsed or flattened condition in which it is desirable to ship it to the user. In this con- ,dition the bottom section II is folded upwardly within the container and the flaps 20 are folded inwardly against the face of the bottom section. When it is desired to erect the outer container from collapsed position, it is merely necessary to press the outer edges of the flattened container inwardly, thereby distending the wall sections I5, I6 and II. As the ilattened container is pressed inwardly along the outer edges of sections I5 and I1 the bottom section spreads toward iiattened,l

' container will be accommodated. By terminating condition as will be seen in Fig. 11, the erection l of the outer container being complete when the bottom section assumes a substantially horizontal position. In this position the bottom edge of 0 the walls I5 are in proximity to two of the free edges of the bottom 'section II,l while the lower -edge of individual side sections I-'I are in proximity tofthe opposite free edges of the bottom section Il.

75 The natural resilient character of the fibrous material employed causes the free naps 20 to rotate toward vertical position upon erection oi the outer container, and these free flaps ordinarily will seat against the side sections I5 and II, as shown in Fig. 4.

In connection with the erected outer container III an inner container or liner I2 is employed, the structure of which is shown in Figs. 1, 3 and 6. As will be seen from Fig. 6 the inner container or liner may be formed from a single blank of ma- 10 terial by cutting and scoring the blank to form a plurality of wall sections 22 equal in number to the number of wall sections in the outer container, for this example, six. To the free side edges of the outer wall sections 22 are secured 15 overlapping portions 23. To the lower edges of the wall sections 22 are attached a number of independently inwardly foldable bottom supporting ilaps 2l. The liner is simply assembled by bringing the portions 23 into overlapping relag3 tion as shown in Fig. 3. The insert is then placed into the outer container and pressed downwardly until the flaps 24 assume a horizontal position against the bottom II of the outer container, as shown in Fig. 1'. container or liner will lie 'inside the upturn flaps 20 of the bottom section.

To complete the assembly of the container, an inner and separate bottom or disk I3 of shape similar to that of a cross-section of the outer con- 30 tainer when erected, is inserted edgewise into the innen liner I2, and one side edge of the bottom is placed against the lower edge of one of the walls 22 between such wall and its flap 24. The disk is then pressed down into the assembled position 35 shown in Fig. l. In order to lock the the container in erect orr set-up condition it is preferred ,to employ a disk I3 which is slightly oversize whereby, when pressed into the position shown in Fig. .1, this disk expands the lower portion of the 43 liner I2 suiilciently to form a tight connection therewith. The container is then ready for use in the usual manner. For instance, it may be loaded with liquid or semi-frozen ice cream and the freezing operation thereafter carried on to 4,5l

provide for uniformity as to quantity in filling 554 successive containers, it is preferred toA provide a series of longitudinal score lines 25 along the individual side walls of the outer container, these score lines terminating at a distance spaced from the bottom of the container. The inner linei is 60 provided with longitudinal score lines 26 valong the side walls 22 thereof. As the container is illled, the inner liner and the outer container will be uniformly and evenly distorted whereby the predetermined volume for a given height of the 65 the score lines at a point spaced above the bottom of the container the bottom of'the container is not distorted out of its polygonal' shape. Thus in the finished product the bottom of the container will be substantially hexagonal in crosssectionand the container will approach, towards the top thereof, a vcylindrical shape.

Ordinarily it will be desirable` to provide some means for closing the top of the container, but 7;.

The lower portion of the inner 25 this may be done in any conventional manner, and does not constitute a part of the present invention. Many satisfactory types of closing devices are available and the particular one selected will depend'upon such factors as cost and strength of materials.

U After the ice cream orother material has been placed in the container and as the freezing is completed. the expansionH of the contents will cause the latterto form with the container a more` or less unitary body. That is to say, the ice cream will hold to the walls of the container. Thereby the bottom'of the container is relieved of a considerable portion of the weight of the ice cream. This action is materially assisted by the tendency of the upper portion of the container to expand intocylindrical shape upon thefreezing of the ice cream.

As shown in the drawings, the freeedges of the inner liner are not secured together in a permay nent manner. It is suflicient that there be an overlap of these free edges, as shown in Fig. 3. This enables the user to assemble the insert with the outer container rapidly and easily. 'I'hat is, the free edges' of the .insert may be overlapped to such extent that portions of the outer wall sections 22 are-in overlapped condition, thereby making the preliminary size of the insert considerably smaller than the fixed size of the outer container.- Thus the insert may be dropped into the container and subsequently expanded-to its ultimate size.

In the assembled container the upwardly extending flaps 20, whichfare between the outer container and the insert, form a jointure between the free edges of the bottom section and the free edges of thevertical walls of the outer container. By expanding the insert upon insertion of the innerl bottom section I3 a tight fit is had. between these upwardly extending aps 20 and the outer container on the one side thereof v and the inner container on the other side thereof. In addition, the inwardly extending horizontal flaps 24 are connected to the insert and as weight is placed upon theinner or auxiliary bottom-section I3 a considerable portion of this weight-is carried by the flaps 24 in the inner insert.` It will be found that the complete container is quite suitable for its intended purpose and is free from points of` weakness which are apt to cause' deterioration of the carton during use and to permit leakage of the contents. Its strength and stability are obtained without the use of metallic bands or other supporting structures on thebottom of the container.

In the embodiment shown in.Figs. 12 and 13 Ivl section 3|. The opposite side of the octagonaly 5 bottom section 3| has integrally connected therewith the intermediate of three wall sections 32. A plurality of independently foldable flaps 33 are secured to the free edges of the bottomsection 3|,.and a score line 34 is provided through 10 the Acenter ofthe bottom section 3l parallel to the edges of the bottom section along which the 4intermediate walls 30 and 32 are connected. As

the bottom section is folded upwardly along line 34 upon formationof the carton, as specified 15 hereinbefore in connection with the hexagonal carton,y it is desirable to cut the central flaps 33 along a line forming the continuation of thzeiscore line 34. The container is then completed as described hereinbefore, an octagonal auxiliary or 20 inner bottom disk being employed to lock the container in erect condition.

Various4 modications of the structures described herein will occur to' one skilled in the art. For example, in many instances it may be de- 25 sii-able to employ a metallicv band along the top of the container in order to insure an even expansion of the materials therein. This band may be of circular shape. Also the bottom and side sections of the outer container may be formed 30 from separate blanks and secured together in a n suitable manner. All such modiilcations and embodiments as come within the spirit of my invention are intended to beI included in the appended claims. 35

I claim:

1. A container, comprising an outer body section, a polygonal bottom section connected to said outer body section alongopposite parallel edges and having free flap portions adapted to 0 line adjacent said body section. said bottom section having a diametric score line parallel to said opposite edges, an inner body section having inwardly extending flaps connected thereto and an oversize inner bottom section positioned adjacent 5 said flaps and pressedV into engagement with said inner body section.

2. A container, comprising a polygonal outer body section, an outer bottom section connected to said body section along opposite parallel edges, 50 Said outer bottom -section having a diametric score line parallel to said opposite edges, and upwardly extending flaps alongI its free edges form. ing a jointure with said body section, an. inner container of similar shape to said outer container 55 andghaving a plurality of inwardly extending flaps resting' adjacent said outer .bottom section, an

oversize inner bottom lsection positioned upon said inwardly extending ilaps and pressed into vengagement with said inner container. w

SAMUEL N. LEOPOLD. 

